Fuel Tank With Sub Components, Component Overview (FWD)

Fuel Supply, Front Wheel Drive (FWD)

CAUTION:
Before beginning repairs on the electrical system:
- Obtain the anti-theft radio security code.
- Switch the ignition off.
- Disconnect the battery Ground (GND) strap.
- On vehicles equipped with Audi Telematics by OnStar(R), switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery.
- After reconnecting vehicle battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows.
- After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar(R), switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module.

NOTE:
- Secure all hose connections with the correct hose clips (same as original equipment).
- Hose VAG1921 clip pliers are recommended when installing spring-type clips.
- Always replace sealing rings and gaskets when assembling.

Fuel Tank With Sub Components, Component Overview

Part I







1 Fuel return line
- From engine
- Mark before disconnecting
- Observe arrow direction on flange
- Clip in right front at fuel tank
2 Fuel supply line
- From fuel filter
- Mark before disconnecting
- Observe arrow direction on flange
- Clip in right front at fuel tank
3 Bolt M8 x 35 with attached washer
- 23 Nm (17 ft lb)
- Secures fuel filler neck and Ground wire -item -9-
4 Over flow hose
5 Rubber cup
6 Retaining ring
7 Fuel filler cap
8 Seal
- Replace if damaged
9 Ground connection
- Installation position/Checking procedure, See Fig. 1
- Make sure that both terminals have good electrical contact
- Mount terminal with bolt -3- for fuel filler neck
- After installing, measure resistance using multimeter (Fluke 83 or equivalent) between metal ring of fuel filler neck and bare metal part of body. Specified value: approx. 0 Ohm
10 Vent line
- To EVAP canister
11 Vent line
12 Vent line
13 Fuel tank
14 Holding clamp
- Observe different lengths
- Installation position: stop (hole) points toward front of vehicle
15 Bolt M8 x 28 with attached washer
- 23 Nm (17 ft lb)

Part II







1 Fuel filler neck
- With expansion tank
2 O-Ring
- Always replace
3 Gravity valve
- Not available as replacement part
- To remove, unsnap valve and pull to top from filler neck
Checking operation:
- Valve upright: open
- Valve turned 45 degrees from vertical: closed
4 Tank protection valve
- Mounted (clipped on) to fuel filler neck
- Ventilates tank to equalize pressure
5 Ground (GND) connection
- Installation position / Checking procedure, See Fig. 1
- Ensure tight fit connection of connector at filler neck
- Tighten contact terminal (tongue) with bolt to fuel filler neck -item 3-
- After installing, measure resistance using multimeter (Fluke 83 or equivalent) between metal ring of fuel filler neck and bare metal part of body. Specified value: approx. 0 Ohm
6 Sealing ring
- Installation position: sealing lip faces fuel filler neck
7 O-Rings
- Different size
- Always replace
8 Vent valve
9 Hose coupling
- To remove, press down on release tab
10 To EVAP canister

Fig. 1 Checking procedure of Ground (GND) connection







NOTE: Check installation position with fuel tank removed

- Install Ground (GND) connection -arrow- as shown.
- Make sure that harness connector for Ground (GND) connection is properly seated on metal ring (Ground clamp) on fuel filler neck.
- Check if contact terminal (tongue) at fastening hole is properly locked in.







- Hold terminal tongue -1- with bolt -2- to fuel filler neck.

CAUTION:
After installing the expansion tank, use ohmmeter to check the electrical connection between metal (Ground clamp) ring on the fuel filler neck and bare metal part (Ground (GND) on Body.
- Specification: approx. 0 Ohm

Fig. 2 Vent valve removing, installing and checking







Removing
- Fuel tank removing.
- To remove unclip valve (laterally) from expansion tank.

Checking
- Close flange -3- with hand.
- Blow into flange -1-:
- Knob -2- in rest position: It should not be possible to blow through
- Knob -2- pressed in direction of arrow: It must be possible to blow through.